1. PAINPOINT DRIVEN OPENING

Are unplanned breakdowns and inconsistent output crippling your aggregate production schedule? For plant managers and engineering contractors, the reliability of core crushing equipment directly dictates profitability. Common operational challenges with primary stone crushers include:

Excessive Downtime for Maintenance: Frequent liner changes and component wear lead to production halts, costing thousands per hour in lost output and labor.
Unpredictable Product Gradation: Inconsistent feed size or wearrelated performance drift results in offspec aggregate, forcing recrushing or product downgrades.
High Operational Costs: Rising energy consumption per ton and the recurring expense of premium wear parts erode project margins.
Vulnerability to Tramp Metal & Uncrushables: Unplanned incidents with contaminant materials can cause catastrophic damage, resulting in lengthy, expensive repairs.

Is your current primary crusher a constant source of operational risk and cost overrun? The solution lies not just in a machine, but in an engineered system built for predictable performance and total cost of ownership.

2. PRODUCT OVERVIEW

The Jaw Crusher is a robust, heavyduty primary crushing machine designed for the first stage of size reduction in quarrying, mining, and demolition recycling applications. Its core function is to compressively fracture large feed material (typically runofmine or runofquarry rock) into manageable sizes for secondary processing.

Operational Workflow:
1. Feed Intake: Large raw material (up to 8090% of crusher gape) is loaded into the vibrating grizzly feeder ahead of the crusher.
2. Compressive Crushing: Material enters the fixed and movable jaw plates. The eccentric shaft drives the movable jaw in an elliptical motion, applying immense compressive force to the rock.
3. Discharge: Crushed material exits through the adjustable discharge opening at the bottom, with size determined by the closedside setting (CSS).

Application Scope & Limitations:
Scope: Ideal for hard, abrasive materials (granite, basalt, river gravel). Suited for stationary plants and mobile tracked setups. Handles a wide variety of feed sizes.
Limitations: Not optimal for soft, nonabrasive stone where other crusher types may be more efficient. Requires consistent feed control to prevent choking. Output tends to be more elongated compared to cone crushers.

3. CORE FEATURES

Deep Crushing Chamber & Optimized Kinematics | Technical Basis: Increased nip angle and longer crushing stroke | Operational Benefit: Higher capacity per stroke and improved reduction ratio from feed to product | ROI Impact: Greater throughput per operating hour reduces unit cost per ton.

HeavyDuty Fabricated Frame with StressRelieved Construction | Technical Basis: Finite Element Analysis (FEA) optimized design with postweld heat treatment | Operational Benefit: Exceptional structural integrity withstands high cyclic loads, preventing frame fatigue cracks | ROI Impact: Extends service life beyond 20+ years under severe duty, protecting capital investment.

Hydraulic Toggle Adjustment & Clearing System | Technical Basis: Replaceable hydraulic cylinder for toggle plate tensioning and overload release | Operational Benefit: Enables quick CSS adjustment for product control and automatic tramp iron release to protect from uncrushables | ROI Impact: Minimizes downtime for settings changes; prevents costly damage from stall events.

HighPerformance Bearing Assembly with Labyrinth Seals | Technical Basis: Oversized spherical roller bearings on a forged eccentric shaft with multistage sealing | Operational Benefit: Sustains high load capacities with minimal heat generation; effectively excludes dust and contaminants | ROI Impact: Drastically extends bearing service intervals (>10,000 hours), reducing lubrication costs and failure risk.

BoltOn Wear Liners with Wedge Lock System | Technical Basis: Reversible manganese steel jaw dies secured by mechanical wedges | Operational Benefit: Allows for rotation/ replacement of wear parts without backing material; reduces changeout time by up to 50% | ROI Impact: Lowers maintenance labor costs and increases equipment availability.

Integrated Motor Base & Belt Drive Guarding | Technical Basis: Unified baseplate for crusher, motor, and sheaves with full perimeter guarding | Operational Benefit: Simplifies alignment during installation; ensures operator safety compliant with global standards (ISO/OSHA) | ROI Impact: Reduces installation time/cost; mitigates site safety liability.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Jaw Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (Uptime) | 9294% (Scheduled & Unscheduled) | >96% Annual Availability| +3% Improvement |
| Wear Life (Jaw Dies Abrasive Rock) | 120,000 150,000 tons per set| 180,000 220,000 tons per set| +40% Improvement |
| Energy Consumption (kWh/ton) Varies by material| Baseline = 100%| Average reduction to ~90% of baseline| ~10% Improvement |
| Tramp Iron Recovery Time (Full Cycle)| Manual clearing can exceed 24 hours| Hydraulic clearing system completes cycle in <15 minutes| ~90% Reduction |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: From 150 TPH to 1,200 TPH (varies based on feed material & CSS).
Feed Opening Sizes: Ranging from 800mm x 550mm up to 1500mm x 1300mm.
Power Requirements: Driven by electric motors from 75 kW up to 250 kW; voltage as per client specification (e.g., 400V/50Hz or 480V/60Hz).
Material Specifications: Main frame – Highstrength steel plate (S355J2). Jaw dies – Premium Manganese Steel (1418%). Shaft – Forged Alloy Steel (42CrMo4).
Physical Dimensions & Weight: Approximate weights from 15 tonnes to 70 tonnes; detailed layout drawings provided for foundation planning.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust seals effective in conditions up to IP65 equivalent protection.

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing Station

Challenge: A large granite quarry faced frequent downtime due to premature jaw die wear (~100k tons/set) and struggled with maintaining consistent CSS manually as operators avoided timeconsuming adjustments.
Solution: Implementation of our heavyduty jaw crusher featuring extendedlife manganese jaws and a hydraulic toggle adjustment system.
Results: Wear life extended to over 190k tons per set. CSS adjustments are now performed during scheduled breaks in <10 minutes. Annual throughput increased by an estimated 8%, while liner costs decreased by 35%.

Urban Construction & Demolition Waste Recycling

Challenge: A C&D recycling plant needed a primary crusher resilient to occasional tramp metal (rebar, steel beams) that could handle variable concrete feed without constant fear of catastrophic failure.
Solution: Installation of our jaw crusher equipped with an automatic hydraulic overload protection system.
Results: The system has successfully performed multiple automatic releases on uncrushable metal objects over two years without damage. This has eliminated related major repair events (~$25k average), ensuring continuous processing contracts are met.

7. COMMERCIAL CONSIDERATIONS

Our jaw crushers are offered in three primary tiers:
1. Standard Duty Series: For consistent feed of moderately abrasive materials; competitive capital cost focus.
2. HeavyDuty Series (Most Common): Includes all features listed above; optimized for maximum lifetime value in demanding quarry applications.
3. SuperDuty Series: Enhanced components for extreme abrasiveness or specific highcapacity requirements.

Optional features include automated lubrication systems integrated weighing sensors monitoring CSS wear metal detection systems on feed conveyor

Service packages range from basic commissioning supervision comprehensive multiyear planned maintenance agreements including parts kits regular inspections

Financing options available through partner institutions include straight equipment lease operating lease structures project financing tailored largescale greenfield developments

FAQ

Q1 What is required foundation preparation this jaw crusher?
A1 Detailed foundation drawings including all static dynamic loads are provided Our engineering team can review your civil plans ensure compatibility minimizing installation delays

Q2 How does this unit integrate existing secondary tertiary crushing screening circuit?
A2 We provide detailed interface data on recommended product conveyor specifications ensure optimal chokefed condition secondary cone crushers Our team can audit your flow sheet recommend adjustments maximize overall plant efficiency

Q3 What typical delivery lead time key spare parts?
A3 Critical wear parts jaw dies toggle plates shafts are held regional stock centers targeting shipment within 72 hours Nonstock items follow standard manufacturing schedule which our sales team provides transparency upon order

Q4 Are performance guarantees offered?
A4 Yes We offer guaranteed capacity based agreed upon material characteristics test reports Guarantees also cover mechanical components against defects specified period subject proper operation maintenance as outlined manual

Q5 Can older existing crushers retrofitted your improved components hydraulic toggle system?
A5 In many cases yes Retrofit kits available popular legacy models extend their life improve functionality feasibility study requires model serial number assessment